Process of molding large articles.



N0.-8 92,143. v PATENTED- JUNE 30, 1908. P. DUPONT.

PROCESS OF MOLDING LARGE ARTICLES. APPLICATION FILED MA-Y1B.10oa.

3SHEE'IS-SHEET 1.

WITNESSES: INVENTOR VFW "HE NORRIS PETERS ca., wasnmcmzv, p. c.

No. 892,143. PATENTED JUNE 30, 1908.

- P. DUPONT.

PROCESS OF MOLDING LARGE ARTICLES.

APPLIOATION FILED 'MAY18. 1906. I

3 SHEETS-SHEET 2.

m a N "S goi i WITNESSES. INVE/VTUR fiM A i Paul Dupan t,

ATTORNEYS 'mr NORRIS ws'rsxs cm, WASHINGYON. 11c

No. 892,143. PATENTED JUNE 30, 1908.

P. DUPONT. PROCESS OF MOLDING LARGE ARTICLES.

APPLICATION FILED MAY 18, 1905.

3 SHEBTE-SHBET 3.

.- l/VVE/VTOI? Bud .Dapwzt I I 81 V I W Arromvfks rm? NoxR'l s PETERScm, wnsumnrou, D. c.

large hollow articles it PATENT OFFICE.

PAUL DUPONT, OF LE CATEAU, FRANCE.

PROCESS OF MOLDING LARGE ARTICLES.

To all whom it may concern:

Be it known that 1, PAUL DUPONT, a citizen of the Republic of France,residing at Le Cateau, Nord, in the Republic of France, have inventedcertain new and useful Processes of Molding Large Articles, of which thefollowing is a specification.

My invention is a method of molding large articles, such as bath tubs,basins, and other hollow articles of manufacture.

In the operation of molding hollow articles of this character, it isvery desirable to compress the sand uniformly upon or around the atternin the moldin flask; but in the met ods heretofore employed in moldinghas been impossible to do this owing to the failure of these methods toproperly distribute the sand prior to the compressing operation.

According to my invention the sand in the molding flask resting upon thepattern during the operation of compressing the same is distributeduniformly prior to the compression thereof, and this distribution of thesand is followed by the application of the pressure required to compressthe sand to the desired density.

My invention further consists in sub'ecting the sand in a two-partmolding flas to pressure between a pattern and a rammer or compressor,and while the parts are under such pressure, locking the rammer orcompressor to one part of the flask; the compressed sand' being confinedbetween the rammer and the pattern during the subsequent operations ofmolding the sand in the other part of the flask.

The invention further consists in reinforcing the pattern by a framecorresponding in rofile tosaid pattern, to prevent it from Bendingduring the first operation of compressing the sand between one rammerand one part of the flask; then releasing the flask from pressure, andwithdrawing the reinforcing means prior to reversing the flask with therammer and the pattern attached thereto.

The invention further consists in reversing a two-part flask, with anattached pattern and a rammer operating to confine a body of sand underpressure, from the hereinbefore described position and to bring thehitherto unused part of the flask into position for o eration; thencharging the unused part of t e flask with sand; thereafter compressingthe sand between the pattern and a second rammer or compressor; lockingthe last Specification of Letters Patent.

Application filed May 18,

Patented June 30, 1908.

1905. Serial No. 261,054.

named rammer to the second part of the flask while the parts are underpressure, and releasing the flask with the attached pattern andcompressors from pressure.

By my method it is possible to obtain a regular and pro ortionatelydistributed pressure on the sanc in the respective parts of the flask. Ihave been able to compress the sand to about fifty (50) per cent. of itsoriginal volume under a pressure of three (3) kilograms per squarecentimeter.

In the annexed drawings, I have illustrated one form of apparatussuitable for carrying my process into effect, but it will be understoodthat other kinds of apparatus may be employed.

Figure 1 is a sectional elevation illustrating a two part flask, and asuspended rammer or compressor in their first positions and incooperative relation to the head and a platform of a power press. Fig. 2is a sectional elevation of the same parts shown by Fig. 1, illustratingthe second positions of the parts, wherein the rammer or compressorenters the cope of the flask and operates on the sand therein todisplace or distribute the sand preliminarily to compression of a chargeof sand between said rammer or compressor and oneside of a pattern. Fig.3 is a similar sectional elevation illustrating the third position ofthe parts, wherein the rammer enters the cope of the flask for its fulldistance and the sand is compressed uniformly and to a desired densitybetween one side of the pattern and said rammer. Fig. 4 is a sectionalelevation illustrating the two part flask in an inverted position, thepattern and the rammer being attached to said flask and holding thecharge of material in a compressed condition. Fig. 5 is a sectionalelevation with the flask and the attached parts in the invertedpositions of Fig. 4, but showing a charge of sand compressed against theother side of the l pattern and confined in the flask by a second rammeror compressor, which is locked to the drag of said flask. Fig. 6 is asectional elevation showing the cope of the flask with the pattern andfirst compressor suspended, the drag and the second charge of sand beingwithdrawn from the pattern in a position free from said pattern. Fig. 7is a sectional elevation showing the cope and drag of the flask withtheir attached compressors or rammers and with their respective chargesofmolded sand in matched positions, the several parts being assembledfor the casting operation. Fig. 8 is a lan view of the flask in ositionon the plat 'orm of a press, illustrating a guide device for the flaskcooperating with one of the uprights of the press, in order to centerthe flask therein. Figs. 9, 10 and 11 are detail sectional elevationsshowing means for looking a pattern in fixed position be tween the partsof a flask, and for locking said parts of the flask to each other, asrequired in the operations of molding the sand and assembling the flaskfor the casting operation.

In carrying my invention into practice, I employ a two part flask, thecope or upper member of which is indicated 'at' A, and the drag or lowermember at B. These parts of the flask may be of any suitableconstruction, dimensions and material, and they are adapted to'beassembled into registering or matching relation, and to be lockeddirectly together or with an interposed pattern 0 of the hollow article,which it is desired to cast. As shown, the cope A is considerably deeperthan the drag B, for the purpose of receiving the body or major portionof the pattern 0. This pattern may be of wood, metal, or other suitablematerial, and it corresponds in shape to the article which it is desiredto cast, said pattern being shown as having a marginal flange c, whichis adapted to fit between the edges of the drag A and cope B, so as toproject outside of the flask. Said marginal flange of the attern C issomewhat thinner than the wall of the pattern and, furthermore, saidflange c is perforated at suitable intervals. The perforations of theflange register with similar perforations in lugs or ears (1, b, of theparts A, B, of the flask, and through these alined openings are adaptedto pass a suitable number of bolts or pins D, see Figs. 9, 10 and 11.Each bolt or pin is slotted for the reception of keys (1 d, adapted toengage with the lugs a, b, of the respective parts of the flask, andeach pin or bolt is furthermore provided with an opening for thereception of a cross pind adapted for engagement with the flange c ofthe pattern C, as indicated by Fig. 9, or With a lug of one part of theflask as in Fig; 11. A suitable number of the pins or bolts D are usedfor holding the members of the flask with an interposed pattern betweensaid members as in Fig. 9, in certain of the operations of molding thesand, or these pins or bolts may be used for attaching the pattern tothe cope A, ofthe flask as in Fig. 10, when the drag and one molded partof the sand is withdrawn from the cope, or the in or bolts may be usedfor connecting or ocking the members A B of the flask directly to eachother, as in Fig. 11, in another of the operations of casting thearticle.

The flask A is reversible with reference to a power press, the latterbeing indicated in Figs. 1, 2 and 3, and for the purpose of reversing orinverting the flask, it is provided with trun nions E on the cope A,whereby said flask may be suspended within a press. I have illustratedthe flask as being adapted for use in connection with platform f ofwhich is adapted to be forced by a piston f toward the press head f.This head is connected with other parts of the press by suitable rods orupright members f and the piston rods f of said press operate in apiston cylinder f i The flask is adapted to rest upon the suitablewheeled truck G, which may be run upon the platform f, or it may bemoved bodil aWa from the press, as required. This truck G is centered onthe platform of the press F by a suitable detent g, the same beingrepresented by Fig. 8, as engaging with one of the rods or uprights f 3of the press. The detent is ivoted to the truck G, so as to be foldablet ereon to the dotted line position indicated in Fig. 8, thus permittingthe truck with or without its load to be run upon or off the press, butin the operation of moving the truck and its load on the press platform,the detent 9 should be turned outward to the full line position of Fig.8, in order that said. detent may engage with one of the press rods f soas to center the truck and the flask on the press platform. This detentdoes not interfere With the rising and falling movement of the platformor the flask, because it is adapted to slide along the press rod f whenthe a hydraulic press F, the I press is operated to raise the flasktoward the head f or to withdraw said flask from said head.

One of the early steps of my process consists in molding the sand in thecope A of the flask, and this step of the process contemplates chargingthe sand into the cope and upon the attern, and thereafter displacingthe sand aterally with respect to the walls of the pattern for thepurpose of distributing the sand to a uniform depth over the pattern,and finally compressing the sand between the flask and the compressor.

With the cope A is adapted to cooperate a rammer or compressor indicatedat H, the interior contour of said rammer corresponding to the profileof the pattern, and said rammer being adapted to enter the cope A whenthe parts are brought together by a relative movement of the flask tothe compressor, or vice versa. This compressor is shown as consisting ofa frame h, a top plate h, and a plurality of internal ribs 72.2. Theribs are arranged longitudinally and transversely within the frame itand against the under side of the plate h, said ribs being suitablyattached to the frame and the plate, and extending lengthwise andtransversely of the compressor. The active surface of the compressor isformed by a suitable filling 72 the frame it, and the plate It, saidfilling consisting of cement or other material which occuies the cornersor angles of the frame. The interior contour of the rammer or compressorconforms to the profile of the pattern, and the ribs 7L protrudeslightly beyond the filling h for the purpose of holding the sand duringthe compression thereof. The dimensions and shape of the frame h of thecompressorcorrespond to the internal dimensions of the cope A, in orderthat the compressor may enter said co e, and the lower edge of the frameit is beve ed or inclined to a sharp edge as at h, whereby the edge isadapted to cut the sand away from the walls of the cope A during theperiod that the compressor enters said cope. The compressor 18,furthermore, provided with suitable openings 2' i in the top late It,and these 0 enings i are adapted to e occupied by suitable pouring gatesI, while the o ening i is adapted to be occupied by a vent or the gatesand the vent may be removed and suitable tern orary formers may besubstituted there or. The filling h terminates above the edge It, toleave a free space at the lower open part of the compressor, so that onthe entrance of the compressor into the cope, the sand is forced awayfrom the wall thereof by the edge h", and the lower part of thecompressor frame h, whereby the sand is displaced and distributeduniformly over the pattern before the sand is compressed between thecompressor and said pattern.

The compressor is adapted to be suspended in a firm osition against theunder side of the press ead by a rod J, the same passin through suitableopenings which are provide in'the ends of the frame h above the plate h,said rod J also passing through the pouring gatesand the vent, as shown.The ends of the rod protrude beyond the com ressor, and they are engagedby suitable lin s or hooks 1c, which are attached to a suspension bar K,and from this bar leads a suitable cable 7c adapted to be coiled on apower Windlass, or the cable may be connected with any other suitablecontrivance for its operation. After connecting the links k to the rodJ, the windlass is operated to draw the cable taut and make the rod Jhold the compressor firmly against the under side of the press head f.

It is found that the pattern C when subjected to the pressure requiredto compress the sand will bend and become missha en.

To overcome thiSobjection, I contemp ate the employment of a reinforcingframe M, which is placed within the flask in a position to haveengagement with the under side of the pattern. This reinforcing frame isshown by Figs. 1, 2 and 3 as consisting of suitable ribs m, attached toa base m, said ribs corresponding in profile to the contour of thepattern C on the under side thereof- The base of the frame is ada ted torest on the truck G, and'within the c rag B of the flask, while the ribsor members m of said reinforcing frame have engagement with the patternat numerous lines throughout its length and width. The frame M is usedin connection with the flask in the pattern during the operation ofmolding the sand in the cope A, and this frame is adapted to be removedfrom the flask and the truck during the subsequent operations of moldingthe sand in the drag, as will hereinafter a pear.

Before charging tie cope with sand, the truck G and the flask are run onthe press platform, and centered below the suspended compressor, thereinforcing frame being in position within the flask and in engagementwith the pattern. The platform and its contained parts are now run up tothe compressor to insure accuracy in the position of said compressorrelative to the cope. The platform is now lowered, the cope A filledwith sand, and the platform again raised. When the flask is raised tothe position indicated by Fig. 2, the compressor enters the flask aboutone half the depth thereof, more or less, and the beveled ed e h of thecomressor operates on the sand to force it away rom the walls of theflask and toward the pattern, said compressor being accurately guidedinto position into the cope A by the walls thereof. A further upwarcmovement of the press and the flask causes the compressor to enter fullyinto the cope to the position shown by Fig. 3, and durin the latter partof this movement of the flas the sand therein is compressed between thecompressor and the pattern, the volume of the sand being reduced fully50 and the sand being compressed uniformly over the surface of thepattern. The next step in the operation consists in looking the comressor H within the cope A for the purpose 0 confining the sand betweenthe pattern and said compressor during the subsequent stages of theprocess, and this locking of the compressor to said flask is secured bythe employment of suitable locking members, such as the rods L, whichare adapted to pass through the wall of the com ressor above the plate hthereof and throug 1 the wall of the cope A, see Fig. 4.

The links k are now disenga ed from the rod J, and the suspension bar liis lowered to have engagement with the trunnions E of the flasksubstantially as shown by Fig. 3. The platform f of the press islowered, and the reinforcing frame M is thereby withdrawn from the dragand the pattern, the flask being suspended below the head of the pressby the links 7c and the bar K. The next step in the process consists inmolding the sand within the drag B of the flask, and at this stage ofprocedure I employ a second compressor or rammer 0. Before placing therammer O in position to enter the flask, the bar K and the links k arelowered sufliciently for the flask to be inverted, the trunnions Eturning within the links 7c, so that the flask will assume the positionand be lowered upon the truck G, as shown by Fig. 4, the pattern C andthe compressor H remaining attached to the flask and being invertedtherewith.

The compressor O corresponds to the internal contour of the pattern O,and it has a wedge shaped or approximately coniform body 0, which isreinforced by internal webs or ribs 0 and is provided with a marginalflange 0 the body 0 being perforated, substantially as indicated byFigs. 5, 6 and 7. The rammer O is adapted to be placed against the underside of the press head, and to be suspended in position against the sameby the rod'J, the latter passing through the marginal flange of saidcompressor and having engagement with the links 7c of the suspension barK. With the flask and its attached arts on the truck G in the positionshown y Fig. 4, the truck is run upon the press platform beneath thesuspended rammer O, and the press is operated to raise the platform f,the truck and the flask, so as to center the compressor O within thedrag B, thus insuring accurate relationship between said compressor Oand the drag. The platform is again lowered to withdraw the drag fromthe compressor, and the flask is charged with sand until it fills thepattern and said drag. The press is again operated to raise the flaskand causes the compressor O to enter the drag and the pattern, theupward movement of the flask being continued until the compressor Oenters the flask and the pattern to the position shown by Fig. 5. Thesand is thus compressed between the hollow side of the pattern and themale compressor O, and said compressor is now locked to the drag B, soas to confine the sand between the pattern and said compressor, anysuitable locking devices, such as the pins O,

being employed for locking the compressor to said drag, see Figs. 6 and7.

The male compressor having been locked with the flask, the suspensionbar K is lowered while the press head and the truck are in their raisedpositions, thus releasing the suspension rod J and permitting the links7: to be connected with the trunnions E of the flask. The press platformand the truck are now lowered, but the flask and its attached parts aresuspended against the under side of the press head, by the links it ofthe suspension bar. The flask is now again inverted so as to restore theparts to their normal positions, and the suspension bar is raised forthe purpose of drawing the cope A and the female compressor H againstthe press head. The next step in the process consists in opening theflask and withdrawing the pattern from the molded sand contained in thedrag and cope, respectively. In performing this operation the pressplatform and a truck as G are run up for the truck to receive the drag Band the compressor 0 together with the molded sand thereon. The keys dare removed from the bolts D and the drag is thus unlocked from thepattern and the cope, after which the press platform is lowered so as towithdraw one molded body of sand from the pattern and with it the drag Band the male compressor O the cope A, the pattern 0, the compressor Hand the other molded body of sand remaining suspended from the presshead in the position shown by Fig. 6. The truck with the drag and itsassociated-parts are now run off the press and another truck is run onto the press platform which is again raised so as to bring the lastmentioned truck into position for receiving the pattern 0. This patternis struck lightly in order to free it from the sand in the cope, andsaid pattern is deposited upon the second truck, the latter beinglowered with the press platform while the cope, the sand therein and thecompressor remain suspended. The second truck with the pattern isremoved away from the press and the truck H containing the drag B,compressor O and sand, is run back into position on the press platform,and the latter with its load is raised so as to bring the two parts ofthe flask and the two bodies of molded sand into matching relation. Theparts'of the flask are now locked together by the bolts D, asrepresented by Fig. 11, and the assembled flask is removed from thepress.

It should be remarked that after molding the sand in the cope A, betweenthe pattern and the female compressor H, and after the flask shall havebeen lowered from the suspended position of Fig. 3, the pouring gates I,I, and the vent I become accessible. These parts can be removedtemporarily and replaced by solid wooden plugs of the same shape as theopenings left in the sand. Sand is now built up by hand around theplugged holes, up to the level of the upper edge of the compressor H,which is level with the flask, the wooden plugs being then removed.After molding the sand in the cope and in the drag, air holes arepricked in each body of molded sand by means of a molders needle, thesame being introduced through the perforated portions of the compressorsH and O. These holes provide for the eXit of gases during the castingoperation. When the two bodies of molded sand, the parts A, B, of theflask, and the compressors H, O, shall have been assembled as shown byFig. 7, the two parts of the mold are locked together, and the mold isready for casting, the metal being poured through the gates, as in theordinary operation.

Having thus described my invention, what I claim as new and desire tosecure by Letters Patent is 1. The process of molding which consists incharging sand upon a pattern within a flask, then distributing the sanduniformly the flask, so as over the pattern by means of a compressorwhich dis'laces the sand laterally of the walls of t e flask without comressing the sand on the pattern, subsequently compressing the sandbetween the pattern and said compressor, and retaining said compressorwithin the flask and in engagement with the compressed sand until thecasting operation is com leted.

2. T e process of molding which consists in charging sand upon a patternwithin a flask, then displacing the sand laterally of the walls of theflask, so as to distribute said sand uniformly over the pattern withoutcompressing the sand against said pattern, thereafter compressing thesand between the said pattern and the compressor, supporting thecompressed sand by a member separate from the flask until the castingoperation is com leted, and withdrawing the pattern from the ask. a

3. The process of molding which consists in charging sand u on a patternwithin a flask, then distributing the sand in uniform depth over thepattern by means of a compressor introduced within the flask andoperating to displace the sand laterally of the walls of said flask,then compressing the sand against the pattern by the said compressor,and retaining the compressor within to act as a support for thecompressed sand, until the casting operation is com leted.

4. he process of molding which consists in charging sand upon a patternheld in a flask; sus ending a rammer or compressor over the flask;closing the parts by a relative movement of one to the other and makingthe compressor displace the sand to a uniform depth over the pattern;compressing the sand between the pattern and the compressor by a furtherrelative movement of the flask and the compressor; and locking thecompressor to the flask.

5. The process of molding which consists in depositing sand upon apattern within a flask; arranging a compressor in the path of the flask;forcing the compressor into the flask and compressing the sand betweenthe pattern and the compressor; and locking the compressor to the flask.

6. The process of molding which consists in charging sand upon one sideof a pattern within a flask, placing a supporting device within theflask and beneath the other side of the pattern for sustaining saidpattern inde endent of the flask, compressing the san against the firstnamed side of the pattern, and then withdrawing the supporting device.

7. The process of molding which consists in depositlng sand on one sideof a pattern within a two part flask; reinforcing the other side of thepattern against bendin under pressure by a reinforcing device placedwithin the drag and disconnected from the flask; compressing the sandagainst one side of the pattern, removing the reinforcing device whichsu ported the pattern; reversing the flask; filling the other part ofthe flask by depositing sand on the other side of said pattern; and thencompressing the sand in the last mentioned part of the flask.

8. The process of molding which consists in depositing sand upon apattern within one of the members of a two-part flask, compressing thesand against the pattern by forcin a compressor into said member of theflask, Tocking said compressor to the member of the flask, withdrawingthe pattern from the flask member, depositing sand upon thecomplementary part of said pattern confined in the second member of theflask, compressing the sand against said attern by forcing a second comressor into t 1e second member of the flask, ocking the secondcompressor to said second member of the flask, withdrawing the patternfrom the second flask member, and assembling the two flask members withthe respective molds in register.

9. The process of molding which consists in compressing a charge of sandbetween one side of a pattern and a compressor within a two part flask;locking the flask and the compressor in fixed relation to each other;inverting the flask with the molded charge confined between the patternand the compressor; compressing another charge of sand etween the otherside of the pattern and a second compressor; locking the flask and thesecond com ressor to each other; again inverting the lask; separatingthe two parts of the flask; withdrawing the pattern; assembling the twoparts of the flask; and then casting between the molded bodies of sandwhile they are confined within the parts of the flask by the compressorsattached to the respective parts.

10. The process of molding which consists in compressing a charge ofsand within one part of a flask between one side of a pattern and acompressor; reinforcing the other side of the pattern against bendingunder the pressure; locking the compressor to one part of the flask;inverting the flask and with drawing the reinforcement for the pattern;then compressing another body of sand in the other part of the flaskbetween a second compressor and the other side of the pattern; lockingthe second compressor to the second part of the flask; again invertingthe flask; opening the flask; withdrawing the pattern; and finallyassembling the two parts of the flask to bring the molded bodies of sandinto until the casting operation is completed. I

distributing it uniformly over the pattern I 13; The process of moldingwhich consists without compressing it against the pattern, in charginsand upon a pattern within a subsequently com ressing the sand againstflask, disp acing the sand laterally of the the pattern by ringing saidcompressor walls of the flask and distributingit by means closer to thepattern, and supporting said compressed sand until the casting operationis completed.

12. The process of molding which consists in charging sand upon apattern Within a flask, displacing the sand and uniformly dis- I quentlycompressing the sand against the pattern by bringing the said compressorcloser to the pattern, and then looking the compressor to the flask.

tributing'it over a pattern without compressing it against said patternby means of an name to this specification in the presence of initialmgbvement (if a compressor wifihin the two subscribing witnesses.

flask, su se uenty compressing t e sand against the gattern by furthertravel of the PAUL N compressor toward the pattern, and allowing thecompressor to remain within the flask Witnesses GEORGES BRAUN, GUsTAVELEGROUN.

of a compressor over the pattern without compressing it against thepattern, subse- In testimony whereof I have signed my

